Saving the planet s water nature s way Electric Aerator Installation Manual EL2 Koenders Windmills A Division of Koenders Water Solutions Inc. 3426 Saskatchewan Drive Regina, Saskatchewan Canada S4T 1H1 Phone: (877) 888-7707 Fax: (306) 721-1496 support@koenderswindmills.com Website: www.koenderswindmills.com
Title TABLE OF CONTENTS Page Table of Contents & Warranty Information 2 Package Contents 3 EL2 Information 4 Theory of Operation 5 Important Information 6 Installation 7-8 Airstone and Freeze Kit Instructions 9 Troubleshooting 10 EL2 Schematic 11 The Koenders Two Year Limited Warranty Warranty covers the product for a period of two years from Date of Purchase, against defects in workmanship or material. The conditions of the Warranty and the extent of the responsibilities of Koenders Windmills under this Warranty are as follows: 1. Koenders Windmills will replace any unit deemed to be defective by Koenders Windmills, due to quality and/or workmanship, within a two year period from the initial purchase date; 2. Products being returned must be returned to the address specified by the Manufacturer freight prepaid, and any warranty product sent to the customer will be sent freight prepaid; 3. Warranty does not apply to product which has been subject to abuse, neglect, accident or incorrect installation; 4. Upon approved Warranty replacement the customers remaining warranty period will be reset to two full years. 5. Warranty does not apply to damage resulting from severe weather factors; * Private Insurance coverage is recommended * 6. When a Pressure Release Valve has not been used, warranty coverage may not apply to damages incurred to a Koenders Aeration system as a result of blocked line. The use of a Koenders Freeze Control Unit is HIGHLY RECOMMENDED in geographical areas where freeze up may be a concern. 7. If parts other than genuine Koenders parts are utilized for repair or attached to a Koenders Aeration system, warranty coverage may be void. 8. Proof of Date of Purchase is required for warranty service. Since the customer is responsible for assembly, set up and installation, please follow instructions carefully, to ensure the validity of warranty claims; 9. If you have any warranty concerns, please contact Koenders Windmills at 1-877-888-7707 in Canada or USA. International customers can call 011-306-721-1495 with any warranty concerns Safety Precautions 1. Unplug the unit before attempting any service or repairs. Return Materials Authorization A return materials authorization (RMA) number must be obtained prior to returning any product for a warranty concern. You can call the KWI warranty department at the following numbers: o Canada and USA 1-877-888-7707 o International (outside Canada and USA) 011-306-721-1495 Failure to obtain a RMA may result in the product being returned to the customer freight collect. Koenders Windmills recommends that, for future reference, you keep this Installation Manual in a convenient location. Serial number: Date of Purchase: Page 2
Package Contents Qty Item Image 1 Electric Aerator 1 100 Roll of Airline 1 Diffuser Airstone 1 Foot Valve 1 Pressure Release Valve Page 3
EL2 Information Effective - The Koenders EL2 Electric Compressor is an effective aeration source to maintain a quality water supply where wind exposure is minimal, and a power source is available. All Weather Protection - The Koenders EL2 compressor comes complete in an enclosed polyethylene case for all-weather protection, simply plug it into any 110-120V power source. Product Placement It is suggested to place the EL2 in a cold, low humidity environment, an outdoor location is ideal. It is not recommended to run the EL2 in a warm, humid environment such as a heated garage or barn. Energy Efficient - The EL2 compressor is a diaphragm pump compressor powered by a 1/3 H.P. 1725 R.P.M. energy efficient motor. Low Amp Draw - The amp rating required to run the EL2 compressor is approximately 1.35 2.5 amps. The low amp draw extends the life of the motor, and helps keep electrical costs within your budget. Diaphragm Design - The EL2 compressor operates with the same diaphragm as the Koenders Freeair Windmill Compressor. Diaphragms should last for a number of years but a visual check on a yearly basis will determine the condition of the diaphragm. High Output - It can produce 1.5 cubic ft. of air per minute at 5 lbs. per square inch pressure with a maximum of approximately 25 P.S. I. more than enough to aerate most farm sized ponds or dugouts. Equalized Temperature - The Koenders electric aerators are vented to equalize the inside and outside air temperatures. Back-Flow Prevention - A foot valve is included as standard equipment with the aerator. Complete System - The EL2 system includes 100 of 3/8 I.D. airline, a pressure release valve and an airstone diffuser, which will increase the oxygen transfer into the water by about 800%. High Pressure Protection The Pressure Release Valve will allow excess pressure to be vented during a blockage, protecting the compressor from the additional wear and tear caused by running under full pressure. Freeze-up Protection An optional freeze control unit is a self regulating system that protects against line freeze-up by monitoring line pressure and by injecting alcohol into the line under freeze up situations due to condensed moisture freezing in the line. A freeze control unit is highly recommended for winter climates. Low Maintenance - Yearly maintenance should include a visual check of the insert valves(1 on the diaphragm and 1 in the foot valve).the teflon disc and spring in the horizontal valve assembly should also be checked on a yearly basis. Also check the drive belt for wear and bearings for excessive noise on a yearly basis. See page 11. Easy Installation The Koenders EL2 Electric Aerator offers a simple plug and play installation process. Page 4
Theory of Operation Under natural conditions in a dugout or pond, oxygen exchange with the environment is not sufficient. In summer, a layer of warm water forms on the surface and floats on a layer of deeper, cooler water. The layer of cold water, having no contact with the atmosphere, becomes depleted of oxygen. Under low oxygen conditions, plant nutrients, metals, and swamp gases are released from the dugout sediments and held by the cold water layer. In fall, air temperature and the surface of the dugout or pond cool rapidly. When the surface reaches the temperature of the cooler, bottom layer, the dugout or pond turns over. This means that the water in the dugout is no longer stratified and mixing of all the dugout or pond water occurs. Nutrients and unwanted compounds become evenly distributed throughout the water. During winter, ice cover prevents the transfer of oxygen from the atmosphere to the water. When oxygen is depleted, microbial activity in the sediments again begins to release unwanted compounds. One of these compounds, hydrogen sulphide, produces the rotten egg smell that often develops in small water bodies in late winter. The ice melts in spring, the surface warms, and the water mixes completely distributing the unwanted compounds throughout the water. Dissolved nutrients become readily available to plants and algae near the surface. As the air temperature increases, the cycle begins again. In order to prevent this cycle of low oxygen conditions from developing, supplementary aeration is required. This adds oxygen to the water and ensures complete mixing of the water so that contact with the atmosphere is maximized. Research has shown that dugouts or ponds should be aerated 24 hours per day, year round. Get more from your water supply Ponds and dugouts last longer with proper, year round aeration and maintenance. Industry studies have shown that aerated water is healthier for all livestock and wildlife. The benefits being overall better health and added weight gain. Environmentally aeration is important because it allows us to make existing water supplies useable rather than constantly prematurely harvesting from our underground water supplies. Aerating frees the water of algae, sludge, toxins and odour and decreases the opportunity to make them insect and parasite nesting grounds. The occurrence of winter kill of fish in aerated water is low. Aeration prevents the pond bottom from becoming anaerobic and producing the rotten egg smell Page 5
Important Information! This EL2 must be plugged directly into an electrical outlet. Do not use extension cords. The use of extension cords will cause the motor to overheat and cut out due to a higher amperage draw and may void warranty. It is highly recommended to use an extra length of airline instead. The Pressure Release Valve is designed to vent into the atmosphere once the line pressure reaches approximately 18 PSI. The maximum the EL2 can produce is 25 PSI. The Pressure Release Valve MUST be installed or warranty may be void. Koenders Windmills suggests that a FREEZE CONTROL UNIT be installed on all electric aerators that will be operating in cold weather climates. When an EL2 is installed where high humidity and freezing conditions occur at the same time, the airline running from the EL2 to the water source can become subject to freeze up due to condensation. The included Pressure Release Valve will help protect the compressor from back-pressure but will not keep the line free of ice. For more information on the Freeze Control Unit refer to page 9. A Foot Valve is supplied with each unit to prevent water from backing up the airline and possibly freezing up. The Foot Valve can be used alone or with the Airstone. For more information on the Airstone see page 9 of this manual The unit is not designed to start while the line is pressurized; the motor has a safety cut-off which may trip while under resistance during start-up. If your unit will not start after it has stopped then try checking the pressure levels and/or venting the line. Moisture naturally builds inside the compressor and airline due to the compressing of air. During the winter this moisture can freeze if the unit is shut off. If you stop the unit during winter please be sure to remove the top cover plate and clean out the water. Failure to do so can cause an ice buildup which can damage internal components. It is best to place the unit in a cold, dry environment to prevent this. Placing it outdoors is ideal, pick a location that will keep snow and rain off of it. Page 6
STEP 1: Installation Attach the airline to the horizontal valve assembly on the top of the electric aerator. STEP 2: Attach the airstone diffuser to the foot valve. STEP 3: Attach the foot valve to the end of the airline that is to be placed in the water. Page 7
STEP 4: Cut your airline into two pieces about 15 inches after it comes off the EL2. Connect the two pieces of hose to the left and right barbs of the Pressure Release Valve. Either direction works. Leave the center barb open. STEP 5: Drop the Airstone Diffuser into the water gently. It is highly recommended to sink it inside a bucket as shown on Page 9. CONGRATULATIONS!!! ENJOY YOUR NEW AERATOR BY KOENDERS Page 8
How the Airstone Works Using an Airstone Diffuser is an excellent way to increase aeration efficiency by 800%. We recommend that the Airstone be installed in a plastic pail to prevent it from stirring up the mud. We also recommend that you run a nylon rope through two sides of the pail, not the handle, so that you can retrieve it at any time. Depending on mineral contents in the water, you may have to clean the Airstone periodically, with Muratic acid (follow chemical supplier s precautions on use of product) or by letting it dry out completely and then brush it off with a wire brush or blow it off with an air compressor. How the Optional Freeze Control Unit Works When an ice blockage occurs in the airline the pressure will increase. As it reached approximately 18 PSI the Freeze Control Kit will activate and start to leak alcohol into the line. This will melt the ice and once the line is clear the Freeze Control Kit will shut off. Typical use will require 1 to 2 tank fills per winter. For the Electric Aerator, the Freeze Control Unit should be strapped to 2 pieces of re-bar, 4 off the ground. We recommend the Freeze Control Unit be as close to the Electric Aerator as possible. The 4 piece of Airline is to be fitted between the Pressure Release Valve and the Isopropyl Tank. The 14 piece of Airline is to be fitted between the Pressure Release Valve and the barbed T. The 4-0 piece of Airline (the Balance Tube) is to be fitted from the top of the Isopropyl Tank and the barbed T. Koenders Windmills recommends filling the tank 1/3 2/3 full of 95% - 99% proof Isopropyl Alcohol (available at most Veterinarian supply stores). Maximum recommended fill is 10 Litres. Page 9
Troubleshooting Q. I stopped the unit and it will not start again when I plug it in. A. The unit will not start up if the airline is pressurized. Disconnect the hose to allow it to vent or let it sit for awhile to naturally reduce pressure and try again later. Q. It doesn t put out as much air out as it used to. A. Inside the compressor is a diaphragm and two types of check valves. These parts naturally wear down due to use. We advise an average lifetime of 3-5 years, depending on use and climate. When they fail the unit will no longer produce sufficient pressure and will be unable to aerate in water deeper than 1-2. We supply a maintenance repair kit to replace these parts and restore functionality. The EL2 unit accepts the same maintenance kit as our single diaphragm windmills. There is also a drive belt in the unit that will wear down over time, replacement belts are available from Koenders. Use of a 3 rd party belt may lead to reduced performance or rapid belt failure. Q. I hear a banging or grinding sound. A. There may be a mechanical problem with the unit. Power it down immediately and remove the compressor assembly from the red body for inspection. You can do this by removing the four screws at the outer edges of the compressor and lifting the unit out. This will not void the warranty. Inspect the internal components and call us at 1-877-888-7707 for technical service. Q. The unit is turning off and on by itself. A. Test your power line to ensure the EL2 unit is receiving stable power. The EL2 motor has a thermal safety cutoff that could also be causing the problem but this is not part of normal operation. Please contact Koenders for technical service. Q. The EL2 appears to be running properly but no bubbles are appearing in the water. A. If it is winter then the answer is likely a buildup of ice in the airline. If you have an inline pressure gauge you check the line pressure. If it is a blockage the pressure reading will be around 25 PSI. You can also check the Pressure Release Valve to see if it has started venting excess pressure. You can try to thaw the line by pouring some Isopropyl Alcohol (90% strength or better) down the airline and leaving it for a day. Use of a Freeze Control Kit is recommended for these situations. If it is during the warmer seasons you may have a leak. Small animals are known to chew on the airline. Q. The EL2 unit feels hot. A. The combined heat generated by the motor and by the compressing air will warm the top cover, this is normal. The unit has a very high heat tolerance so do not be concerned. Page 10
EL2 Schematic Page 11